Cement-making.



UNITED STATES PATENT OFFICE.

HERBERT ABRAHAM, OF BOUNDBROOK, NEW JERSEY, AN'D HAROLD HAINES, OF

NEW YORK, N. Y., ASSIGNORS '10 IMPEBVIOUS PRODUCTS COMPANY, A CORPORA- TION OF NEW YORK.

' CEMENT-MAKING.

No Drawing.

To all whom it may concern:

Be it known that we, HEBRERT ABRAHAM and HARoLo W. HAINES, citizens of the United States, the former a resident of Boundbrook, county of Somerset, and State of New Jersey, and the latter a resident of the borough of Manhattan, New York city, New York, have jointly invented certam new and useful Improvements in Cement- Making, of which the following is a specification.

Our invention relates to the production of water-proof hydraulic cement, and the production of miscible pastes for use in the gaging water employed in the preparation of said waterproof materials, and to the accomplishment of these results preferably without impairing the strength of the finished cement.

Many attempts have been made to render hydraulic cement waterproof, but as far as we are aware, none of these have proven satisfactory. In some cases a very limited degree of water-tightness has been secured, but generally at the expense of the strength of the finished product, and this decrease in strength has often unfitted such product for commercial use. Thus the addition of fatty bodies or soaps, whether soluble or insoluble, greatly decreases the strength of the hydraulic cement, if used in more than insignificant amounts, while adding greatly to the cost. Even when added in small quantities they notably affect the strength without imparting any marked waterproofing efi'epts.

By means of our invention we have entirely overcome all of these objections, have succeeded in obtaining a satisfactory hydraulic mement, mortaror concrete that is substantially waterproof or water-tight at a very moderate cost, and which will not deteriorate or decrease in efliciency during service. lVe have accomplished this in our preferred method, not only without materially diminishing the strength of the fink ished structure, but in fact in most cases have been able to increase its strength, especially with lean mixtures.

lVe will now proceed to describe the preferred embodiment of our improved process and product.

In carrying out our improved process, we

Specification of Letters Patent.

Patented Apr. 6, 1915.

Application filed March 9, 1910. Serial No. 548,114.

mix a suitable carrier, preferably a more or less insoluble inorganic hydroxid, capable of forming with water a viscous lastic mixture, such as slaked lime, in the orm of a paste, with a suitable proportion of a viscous unsaponifiable bituminous liquid which must be so chosen that it will not materially lessen the strength of the finished cement. Certain liquid asphaltums or asphaltum oils have been found suitable, and indeed some of them materially increase the strength of the finished cement. The, bituminous liquid is preferably added in small quantities at a time and the mixture triturated or ground during suchadditions to intimately mix the ingredients together. We then add water to the resulting mixture, preferably in small quantities at a time, and preferably continue the said tritu ration or grinding until a suitable proportion of water has been incorporated to render the paste miscible with water Without liberation of the bituminous liquid. We thus produce a miscible paste suitable for use in the gaging Water ordinarily employed in preparing hydraulic cement,mortar and concrete, which paste is miscible with either cold or hot water in any proportions without liberation of the bituminous liquid even on long standing. This miscible paste is then mixed with the gaging water and the resulting liquid incorporated with the hydraulic cement, mortar or concrete in the ordinary manner.

During the process of settlng, the inorganic hydroxid which we preferably employ as the carrier for the bituminous" matter, reacts chemically, thereby increasing the strength of the resultant product. In thisre-action, the inorganic hydroxid, being a basic body, may combine chemically with the acidic constituents present, such as silica or else it may, act with the carbon dioxid absorbed froifi the atmosphere to form carbonate. The bituminous liquid does not undergo any chemical change during the process of setting, but is retained mechanically in the pores of the structure of the cement, mortar or concrete, or of the structure composed of the chemically combined hydroxid and cement, mortar or concrete, without exuding or leaching out with the surplus water as the product sets and dries. The resultstance, capable of forming with water a viscous plastic mixture, may be employed as carrier, we prefer to use a ydroxid for the reasons herein mentioned, and particularly slaked lime on account of its abundance and cheapness. Preferably the lime should be pure. We have found that limes known commercially as fat limes or finishing limes are best suited to our purpose, for they will not result in the formation of coarsegrained gray pastes which are liable to permit the asphaltum to separate on dilution, as is the case with the impurer varieties. WVe are likewise influenced in selecting pure limes, by the fact that the magnesia existing in the impurer varieties hydrates with difficulty, and the presence of anhydrous mag nesia is generally recognized to exert a deleterious action on .cements. lVe hydrate unslaked lime forming a paste containing preferably an equivalent of one part by weight of the anhydrous lime (calcium oxid) to one and a half parts by weight of water. We then mix two and a half parts by weight of this paste with preferably two parts by weight of a viscous, unsaponifiable bituminous liquid. This we preferably add in small quantities at a time to the lime paste, triturating or grinding the mixture in a suitable apparatus during such additions. Any suit-able apparatus may be used for this purpose, as for example, the triturating machine ordinarily used in grinding putties, which is generally known as an edge runner or chaser. The mechanical manipulation 0r trituration intimately mixes the ingredients together, and is preferably continued until the mass possessses a uniform color and a smooth texture. Vater is then added, preferably in small quantities at a time, and preferably the grinding or trituration is continued, although any suitable method of mixing may be employed atthis stage of the process. We prefer to add water to the paste until the resulting mixture attains a uniform smooth buttery consistency and becomes misclble with water in all proportions without causing any separation of the asphaltum oil. This miscible paste is now adapted for use with the gaging wa ter ordinarily employed in making hydraulic cement, mortar and concrete. The resulting cement, when set, is thoroughly waterproof and possesses great The actual waterproofing however, is ef-" the absorption of external moisture. It Will-r be noted that the miscible paste itself 1 the property of mixing with water, after it'has once been allowed to dry the air'or otherwise. y

In place of the calcium hydrom'd or i a I I lime, any other suitable more or less insoluble inorganic hydroxid capable of forming with water a viscous plastic mixture as, for example, iron hydroxid, aluminum hydroxid, etc., maybe employed with more or less satisfactory results. 5

While any other suitable carrier may be employed, if desired, such as plastic clays or the like, and the benefits of our invention in some of its features may be realized to a greater or less extent, we prefer to use as a carrier one of the inorganic hydroxide, as they serve to increase the strength of the resulting product because of their lmion with the aggregate, whereas the use of an inert inorganic substance, such' as plastic clays, tends to decrease the strength.

We are aware that it is not new to intro duce hydrated lime alone into cement mixtures, and that, when thus introduced, itincreases the plasticity and ease of working of the mixture, and serves, to a limited extent.

' to reduce the porosity of the structure with which it is combined. It faib, however, to render the cement waterproof. As far as we know, it is entirely novel to employ lime orany equivalent inorganic hydroxid, or any more or less insoluble inorganie sol stance capable of forming with water a viscous plastic mixture, as a vehicle for carrying and introducing an unsaponifiable bituminous liquid, into the structure of cement, mortar or concrete. Attempts of this general nature have been made, but, as far as we are aware, have failed. For example, the use of solid bituminous? matter with clay as the carrier, has been suggested. A satisfactory waterproofing effect, how ever, cannot be obtained from a solid bituminous substance as thus employed. The bituminous matter must be ofthe proper consistency, neither too stiff or solid, nor too thin or liquid, as set forth below.

\Vhen lime is used as the carrier or vehicle for introducing the asphaltum in our prochaltiuih""oil""s h-"tlalled, because bf its proper consistency may be employed, such I asphalt will inhibit the subsequent addition factory waterproofing eifects.

as bitumens, tars and pitches of a hydrocarbon nature, as'for example, coal tar pitch, or-the like.'- The bituminous substance best adapted for our purpose must at ordinary tern ei'atures beneither too liquid nor too We have found that, if it is toothin o'r'idi quid, it is not apt to be efiectively retained in the pores of the hydraulic cement and that it will, moreover, fail to give the best waterproofing qualities even if it be actually retained- On the other hand, 1f it is too stiif or solid, it will fail to distr bute itself properly in the pores of the finished structure, and will in that case behave as an inert sul stance without imparting satisd We have found that under the latter circumstances the set cement is actually weakened. A viscous unsaponifiable bituminous liquid, such as asphaltum oil or coal tar pitch, gives the best results. It is sufficiently liquid both to unite intimately with the carrier and the water to form the miscible paste, and to dis-' tribute itself properly in the pores of the cement, mortar or concrete, and also sufhciently viscous not to exude or leach out during and after the process of setting. We have found, moreover, that viscous liquids of this description will not be displaced from the pores of the set cement, mortar or concrete, .or permit water'to permeate even when subjected to considerable hydro static pressure.' When the liquid asphaltum is added to the calcium hydroxid, the latter should'be in the form of a still paste. We have found that if the paste is too dry, the

and incorporation of water; and that if too moist, the asphalt itself cannot properly be incorporated.

The process of titurating the lime paste with the liquid asphaltum, is carried on preferably in the cold. This trituration breaks up the lime and causes both the lime and the' bituminous liquid to be intimately mixed and incorporated with each other in a very fine-state of division. We have found that themere stirring of the ingredients together not as satisfactory as a trituration or grinding. A grinding action, such as is effected by the use of the above mentioned type of machine, gives the best results.

' The addition of too much ,asphalt will rehHer-the paste incapable ofbeing mixed with water. In practice, we have found that it is nfit f advisable to incorporate more than two parts by weight of asphalt with the equivalent of one part by weight of the anhydrous lime. The capacity-of different hydroxids for carrying T the bituminous greatly.- Whereas; in the case weight of asphaltum oil may be incorporated with the equivalent of one part by weight hydroxid about three parts by weight of of calcium hydroxid about two parts *by 'of the anhydrous oxid, in the case of iron asphaltum oil maybe incorporated, and with aluminum hy'droxid about five parts by weight. It is obviously desirable that the; resulting paste should can the maximum quantity of asphaltum an the minimum quantity of water consistent with easy and complete miscibility with the gaging water.

In using the paste the best results will generally be obtained when the volume of asphaltum oil introduced approaches the volume of voids contained in the mixture of cement and aggregate. The presence of too large a quantity of asphaltum tends to weaken the strength of the finished product. This will bethe case when the volumeof asphaltum exceeds the volume of pores or voids or interstices in the structure, for it will then tend to separate and prevent the contiguous particles from bonding properly. A decrease in the volume of asphaltum introduced usually decreases the waterproofing efi'ect. This, however, may be compensated for by an increased thickness of the treated layer of cement, mortar or concrete, and we have found in practice that in this manner a very efiicient waterproofing may be imparted by introducing a" volume of asphaltum considerably less than the volume of voids.

The volume of voids will to a certain extent vary with the varying conditions of each case. Thus the total volume of the pores, interstices or voids in the finished product will vary, for example, with the difierentkinds of sand used. The finer the sand or thelarger-the amount used in the mixture, the greater will be the said volume of voids. In this latter case a relatively larger quantity of bituminous liquid would obviously be required than when for example, a coarser or graded variety ofsand, or a richer mixture were employed. In general, the addition of 10% by weight of our miscible paste based on the combined weights of sand and cement gives satisfacto ry results. With concrete, the crushed stone'- 'or gravel should be disregarded in making this calculation, for these substances do not materially influence-the total volume of voids.

Cement, mortar and concrete waterproofed as described will bond equally well with surfaces of an untreated material as with surfaces which have similarly been waterproofed, and the addition of our waterproofing paste does not interfere, as far as we have been able to ascertain, with the setting of the mixture.

We prefer to use a bituminous liquid free'from volatile ingre-x' exposure to the elements. The presence of the bituminous liquid renders the; cement structure more highly resistant to the action of the elements, for it prevents access of moisture and frost, and the formation of surface checks and expansion cracks. It likewise serves to preserve any steel that may be used for reinforcing purposes, and to protect it from rusting in the manner of bituminous paints, and without interfering with the bond between the metal and the-cement, mortar or concrete.

In many instances it is desirable toimpart to the cement structure a color other than that characteristic of ordinary cement. It is not new to mix certain inert mineral pigments with the ingredients of the aggregate to produce colored decorative eifects. These pigments are usually added in small quantities, for it requires but a small amount of an intense pigment to modify the natural color of the mass. In our improved process this coloring may be advantageously effected by grinding a suitable percentage of the pigment with the ingredients of the miscible paste. The paste may, therefore, be advantageously used as a vehicle for conveying and distributing the pigment throughout the cement mixture. It will effect this more uniformly and with greater ease than would be the case if the pigment were incorporated with the'aggregate in a dry state. The pigment may be mixed with the paste either before or after the asphaltum has been added, without apparently affecting its miscibility. The percentage of pigment used should be maintained as low as possible for it is an inert substance, and as such tends to weaken the structure. If the pigment exists in the form of a more or k s insoluble inorganic substance capable of forming with water a viscous plastic mixture, it may obviously serve to replace the hydroxid either wholly or in part, as a carrier for the bituminous liquid. As an example, we have in some cases found it desirable to incorporate one part by weight of strong natural red oxide of iron with five parts by weight of the miscible paste. It will, of course, be understood that other inert mineral pigments, such as yellow ocher, lamp black, lime proof greens and the like, may be similarly employed in suitable amounts.

To avoid repetition, especially in the claims, we use the word cement in its more or less popular sense to include all hydraulic cement, mortar, concrete or artificial stone made with hydraulic cement.

By means of our improved process a very 1 large proportion of bituminous matter to carrier may be incorporated into the cement, mortar or concrete. In most cases the proportion of bituminous matter will be in ex cess of that of the carrier, and where the preferred form of our improved process is 1. The process of making a paste miscible with water, adapted for use withthe gaging water used in preparing hydraulic cement' or the like which consists in mixing a substantially insoluble inorganic substance capable of forming with water a viscous plastic mixture, water, and a viscous unsaponifiable bituminous liquid which will not materially lessen the strength of the cement in suitable proportions. H

2. The process of making a paste adapted for use with the gaging water used in preparing hydraulic cement, or the like, which consistsin mixing a substantially insoluble inorganic substance capable of forming with water a viscous plastic mixture, and water in'suitable proportions, and adding to the paste thus formed a suitable proportion of a viscous unsaponifiable bituminous liquid which will increase the strength of the cement, the mixture being triturated or ground until of a uniform color and smooth texture, and then adding water during the triturating or grinding until the resulting paste becomes miscible with water without liberation of .the bituminous liquid.

3. The process of making a paste adapted for use with the gaging water used in preparing hydraulic cement, or the like, which consists in mixing a paste of calcium hydroxid with a viscous unsaponifiable bituminous liquid which will not materially lessen the strength of the cement and water in suitable proportions so that the paste becomes miscible with water.

' 4. The process of making a paste adapted for use with the gaging water used in pre paring hydraulic cement, or the like, which consists in mixing a paste of calcium hydroxid with a viscous unsaponifiable bituminous liquid which will increase the strength of the cement in suitable proportions, the said liquid being added in small quantities at a time, and the mixture being triturated or ground during such additions until of a uniform color and smooth texture, and then adding water and mixing the resulting product until the'paste becomes miscible with water without liberation of the bituminous liquid.

5. The prosess of making a paste adapted for use with gaging water in preparing hydraulic cement, or the like, which consists in intimately mixing a viscous un'saponifiable bituminous liquid which will not materially weaken 'the cement, a suitable carrier therefor and water, the amount of bituminous liquid thus mixed being in excess of the amount of the carrier.

6. The process of making a paste adapted unsaponi able bituminous liquid which will not materiallg weaken the cement, a suitable carrier capa e of formin with water a viscous plastic mixture, and water.

7. The process of making a paste adapted for use with gaging water in preparing hydraulic cement, or the like, which consists in mixing in suitable proportions, and in a suitable -manner, a more -or less insoluble inorganic substance capable of forming with water a viscous plastic mixture, a suitable pigment, water, and a viscous unsaponifiable bituminous liquid which will increase the strength of the cement.

8. The process of preparing waterproof cement, or the like, which consists in internately mixing in suitable proportions, a substantially insoluble inorganic hydrox1d capable of forming with water a viscous plastic mixture, water, and a viscous unsaponifiable bituminous liquid which will increase the strength of the cement, mixing thepaste thus formed with gaging water, and mixlng the resulting liquid with cement constituents before setting.

9. The process of preparing waterproof cement or the like, which consists in intimately mixing a viscous unsaponifiable bituminous liquid which will not materially lessen the strength of the cement and a suit able carrier therefor, and in combining therewith water in a manner and in amounts until a miscible paste is formed from which the bituminous liquid will not be liberated when the paste is mixed with additional water, mixing such paste with gaging water, and mixing the resulting liquid with other constituents of cement before setting.

10. A miscible paste for use with gaging water in preparing hydraulic cement, or the like, containing a substantially insoluble inorganic substance capable of forming with water a viscous plastic mixture, a viscous unsaponifiable bituminous liquid which will not materially weaken the cement, and water in suitable proportions.

11. A miscible paste for use with gaging water in preparing hydraulic cement, and the like, containing two parts by weight or less of a viscous unsaponifiable bituminous liquid which will increase the strength of the cement, the equivalent of one part by weight of anhydrous lime, and suflicient water to render the paste readily miscible.

12. A miscible paste for use with gaging water in preparing hydraulic cement, or the like, containing liquid asphaltum of a character to increase the strength of the cement,

slaked lime, and water, combined in suitable proportions and triturated or ground together.

13. A miscible paste used with gaging water in preparing hydraulic cement, or the like, containing intimately mixed together a viscous unsaponifiable bituminous liquid of a character not to materially lessen the strength of the cement, water, and a suitable carrier therefor.

14. A miscible paste for use with gaging water in preparing hydraulic cement, or the like, containing a viscous unsaponifiable bituminous liquid of a character to materially increase the strength of the cement, a substantially insoluble inorganic .hydroxid ca pable of forming with water a viscous plastic mixture, and water, all mixed and combined in suitable proportions.

15. A miscible paste for use with gaging water in preparing hydraulic cement, or the like, containing intimately mixed together, a viscous unsaponifiable bituminous liquid which will not materially weaken the cement, a suitable colored pigment capable of forming with water a viscous plastic mixture, and water.

16. A colored miscible paste for use with gaging water in preparing hydraulic cement, containing a viscous unsaponifiable bituminous liquid which will increase the strength of the cement, a somewhat insoluble inorganic substance capable of forming with water a viscous plastic mixture, a pigment, and water, all intimately mixed and combined in suitable proportions.

17. A hydraulic cement, treated to make it waterproof, containing therein, when set, a substantially insoluble inorganic substance and a viscous unsaponifiable bituminous liquid which does not materially weaken the cement.

18. A hydraulic cement, treated to make it waterproof, containing in addition to cement constituents, inorganic derivatives of a substantially insoluble inorganic hydroxid, and also a viscous unsaponifiable bituminous liquid distributed in the pores of the resulting product which increases the strength of the cement.

19. A hydraulic cement, treated to make it waterproof, containing inorganic derivatives of calcium hydroxid in excess of those normally present in the untreated cement, when set, and also a viscous unsaponifiable bituminous liquid distributed in the pores of the cement which does not materially decrease the strength of the cement.

20. A waterproof hydraulic cement, made waterproof by the presence in its pores of a viscous unsaponifiable bituminous liquid of.

ment and a viscous unsaponifiable bituminous liquid distributed in the pores of the cement which does not materially weaken the cement 5 23. A colored hydraulic cement, treated to e it waterproof, containing in addition to cement eonstitutents, when set, a substantially insoluble inorganic substance, and a viscous ponifiable bituminous liquid of 1 v to increase the strength of the cement, and a. finely divided suitable pigment.

In testimony whereof, we have signed our names to this specification, in the presence of two subscribing witnesses.

v HERBERT ABRAHAM. HAROLD W. HAINES. witlllgesses: S

nwm EGER, E. A. Nrenenmusnn. 

